Tools & PPE
- Basic hand tools: metric socket/ratchet set, extension, screwdrivers, pliers.
- Injector socket or small open-end deep socket to fit cold-start injector hex.
- Torque wrench (for installation torque to manufacturer spec).
- Multimeter (auto-range digital).
- Fused jumper lead (1–2 A fuse) or adjustable bench power supply to safely apply 12 V for bench/functional test.
- Fuel pressure gauge (low-pressure for the feed side if applicable) / fuel catch container and hose.
- Fuel-line clamp or pinch pliers.
- Clean shop rags, soft-bristled brush, parts cleaner (diesel-safe).
- O-ring pick, small seal installer tool.
- Replacement parts: cold start injector (OEM part), correct O-rings/seals, crush washers or copper washers if used, replacement mounting screws if damaged.
- Anti-seize or light engine oil for O-rings, dielectric grease for electrical connector.
- Safety: safety glasses, nitrile gloves, fire extinguisher rated for flammable liquids, good ventilation, wheel chocks.

Safety precautions (must-read)
- Work in a well-ventilated area; no open flames or smoking.
- Chock wheels, set parking brake, key out of ignition.
- Disconnect negative battery terminal before starting work (except when performing live electrical tests — see below).
- Relieve fuel system pressure before disconnecting fuel lines to avoid spray. Collect fuel in an approved container.
- Use a fused jumper lead when applying battery voltage to any injector to prevent short circuits.
- Always wear eye protection and gloves when dealing with fuel.
- If the vehicle is common-rail/high-pressure diesel, do NOT loosen high-pressure lines — only low-pressure cold-start injector lines should be handled; refer to service manual if unsure.

Overview
On many Hino FD/FE/FF/SG/FA/FB diesel engines the “cold-start injector” (cold start valve) is a solenoid valve that supplies a small extra amount of fuel during cold cranking. Procedure covers diagnosis, removal, bench/functional test, replacement and reinstallation.

Step-by-step procedure

1) Preliminary checks and diagnosis
- Verify complaint: hard starting only when cold, white exhaust on start, rough idle only until warm.
- Check related items first: battery state, starter cranking speed, glow plug system (if present), fuel filter, fuel supply.
- Scan ECU for codes affecting cold-start strategy (coolant temp sensor, air temp sensor, ECU outputs).

2) Locate the cold-start injector
- The cold-start injector is usually mounted on/near the intake manifold or throttle body area and has a small fuel supply hose and a 2-pin electrical connector. Consult the workshop manual or parts diagram for exact location for your engine model.

3) Prepare vehicle & relieve fuel pressure
- Chock wheels, engage parking brake, disconnect negative battery terminal.
- Remove fuel cap to relieve tank vapor pressure (if needed).
- Relieve low-pressure fuel supply by loosening bleed screw (if applicable) or following the factory procedure. Catch fuel in container.
- Clamp the return line downstream of the injector if you plan to bench-functional-test the valve on-vehicle.

4) Access & clean
- Clean area around injector thoroughly so debris doesn’t fall into fuel system when you open connections.
- Remove any intake ducting or brackets blocking access.

5) Electrical test (static)
- Reconnect battery for electrical checks only, or use a separate 12 V supply.
- Disconnect the injector electrical connector.
- Set multimeter to ohms. Measure resistance across the two injector terminals. Expected: low resistance (solenoid coil) — consult Hino service manual for exact ohm spec for your engine. If open or infinite resistance, the coil is open and injector requires replacement.
- With connector unplugged, check for proper voltage at the harness while cranking (or commanded by ECU) using a fused jumper or scan-tool command. Typical test: one terminal should be switched ground or positive depending on wiring. If no control voltage present when ECU commands, suspect wiring/ECU.

6) Functional test (on-vehicle)
- Clamp return line and position a small hose and container under the injector fuel outlet to catch spray.
- Using a fused jumper lead (1–2 A fuse) or bench supply, briefly apply 12 V across the injector terminals for a short pulse (0.5–1 sec) while the fuel pump is on (or prime fuel supply). Injector should click and emit a fine spray of fuel. If it does not click or spray, it is faulty.
- CAUTION: only momentarily energize to avoid flooding, excessive fuel, fire risk. If you’re unsure, remove and bench-test.

7) Removal
- Disconnect battery negative terminal again.
- Disconnect the electrical connector and fuel feed hose (catch fuel). Remove any retainer bracket.
- Remove mounting bolt(s) and extract the cold-start injector straight out. Use an injector socket if necessary. Be careful not to damage injector tip or manifold seat.
- Inspect the injector O-ring/seal and the injector bore for debris or scoring.

8) Bench test (off-vehicle)
- If you have a bench supply: clamp the injector in a vise padded with soft jaws, make a fuel feed from a hand pump or low-pressure supply, and apply fused 12 V pulses to confirm operation and spray pattern. Watch for irregular spray, leaking at body, no spray, or slow response — replace if faulty.
- Do not pressurize above rating; this is a low-pressure test.

9) Replace seals & install new injector
- Always replace O-rings/seals when refitting. Lightly oil new O-rings with clean diesel or engine oil; do not use petrol-based solvents that dry seals.
- Install new injector into bore, align and fit any bracket or locator. Tighten mounting bolts to manufacturer torque spec (consult manual). If you don’t have the exact number, tighten snugly but do not over-torque; over-torque risks damage.
- Reconnect fuel hose, replace crush washers if fitted, reconnect electrical connector (apply dielectric grease to connectors).

10) Prime and test
- Reconnect battery negative terminal.
- Prime fuel system by using the fuel pump prime procedure (turn key to ON to run pump for a few seconds several times) until pressure/stable flow is achieved.
- Check for any fuel leaks around the injector and fittings.
- Start engine cold and observe starting behavior. If previously cold-start issue is resolved, observe for normal idle and no leaks. Re-scan for codes.

Common pitfalls and how to avoid them
- Not relieving fuel pressure: will cause fuel spray and injury. Always relieve before disconnecting lines.
- Applying battery voltage without fuse or without clamping return lines: can flood intake or cause fire. Use a fused jumper and very short pulses.
- Reusing old O-rings/seals: leads to fuel leaks and air ingress; always replace seals.
- Over-torquing injector hardware: can crack the injector or manifold; use correct torque.
- Misdiagnosing: cold-start problems can be caused by coolant or intake air temp sensors, ECU inputs, glow plugs, or fuel supply; test these first.
- Confusing glow plug fault for cold-start injector fault: check both systems.
- Not cleaning area before removal: debris can enter intake/manifold and cause engine damage.
- Using high-pressure common-rail tools/procedures on low-pressure cold-start injector: be aware of system type. If engine is common-rail, don’t loosen high-pressure lines — refer to manual.

Replacement parts typically required
- New cold-start injector (OEM preferred).
- Injector O-rings/seals (specific to injector).
- Crush washers or copper washers for fuel lines (if present).
- Possibly mounting bolts or brackets if corroded or damaged.
- Fuel filter (if contaminated fuel suspected) — consider replacing.

Notes on tool usage
- Multimeter: set to ohms for resistance check, DC volts to check harness voltage while cranking/commanded. Probe across injector terminals; avoid shorting terminals to body.
- Fused jumper lead/bench supply: always include a fuse in series at ~1–2 A to protect wiring and the injector coil. Pulse only briefly (0.5–2 seconds) for functional checks.
- Fuel pressure gauge: attach to low-pressure test port if present; used to verify supply to injector. Do not use for high-pressure common-rail lines unless you have proper test port and gauge rated for the pressure.

Final checks
- Verify no leaks, correct engine start behavior, and clear any diagnostic trouble codes.
- If problems persist after a known-good injector, investigate sensors and ECU outputs affecting cold-start strategy.

If you have the exact engine code (J05, J08, etc.) and year, consult that Hino workshop manual for precise resistance specs and torque values before final installation.
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